Cast-Rolled Aluminum Wire: Alloys, Properties, and Applications

1. Key Alloy Series
Cast-rolled aluminum wires are primarily manufactured using the following alloy families:

• 1xxx Series (Pure Aluminum):
  • 1350 (99.5% Al): Optimized for electrical conductivity.
  • 1370 (99.7% Al): Ultra-high purity with superior conductivity for precision electronics.
• 3xxx Series (Al-Mn): Enhanced workability and moderate strength.
• 5xxx Series (Al-Mg): Excellent corrosion resistance, suited for marine environments.
• 6xxx Series (Al-Mg-Si): Balanced strength and formability for general engineering.

2. Defining Properties

• Cost-Effective Production: Achieved through continuous casting-rolling processes, enabling high-volume output.
• Surface Characteristics: A thin segregation layer (oxide-rich) forms due to rapid solidification, requiring post-processing for critical applications.
• Electrical Performance:
  • 1xxx alloys (e.g., 1350, 1370) deliver 61–62% IACS conductivity, ideal for power transmission.
  • 1370 alloy minimizes resistivity for high-voltage and precision electronic components.
• Mechanical Behavior:
  • Moderate tensile strength (e.g., 1350: ~80 MPa; 5052: ~210 MPa).
  • Limited fatigue resistance compared to heavily processed alloys.
• Corrosion Resistance: 5xxx and 6xxx alloys excel in harsh environments due to Mg/Si content.

3. Primary Applications

• Electrical Infrastructure:
  • Overhead power lines, busbars (1350 alloy).
  • High-voltage cables, transformer windings, and microelectronic connectors (1370 alloy).
• Automotive: Non-structural components (e.g., wiring harnesses, trim) using 5xxx/6xxx alloys.
• Construction & Consumer Goods:
  • Fasteners, rivets, and extruded profiles (6063 alloy).
  • Decorative elements, HVAC systems, and packaging.

4. Technical Limitations

• Surface Imperfections: Segregation layers and micro-porosity necessitate additional machining for high-precision uses.
• Strength Constraints: Pure aluminum alloys (1xxx series) lack the mechanical robustness required for load-bearing applications.
• Certification Challenges: Rarely meet stringent aerospace or defense standards (e.g., AMS, NADCAP) due to inherent process-induced microstructure variations.